Methods of forming barrier rib microstructures with a mold

Abstract

In one embodiment the present invention relates to microstructured articles (e.g., barrier ribs formed by a method that comprises providing at least one discrete coating of slurry on a transfer sheet).

1 . A method of making barrier ribs for a plasma display panel comprising: providing a transfer sheet; 
 coating the transfer sheet with at least one discrete coating of a curable composition comprising 
 at least one inorganic particulate material,  
 at least one curable organic binder,  
 and at least one diluent;  
   transferring the discrete coating onto a substrate; p 1  contacting the discrete coating with a mold suitable for forming barrier ribs;    curing the curable composition; and    removing the mold.    
   
   
       2 . The method of  claim 1  wherein the transfer sheet is coated with at least two discrete coatings.  
   
   
       3 . The method of  claim 1  wherein the transfer sheet is provided on a substantially planar rigid support.  
   
   
       4 . The method of  claim 1  wherein the transfer sheet is provided on a roll.  
   
   
       5 . The method of  claim 1  wherein the step of transferring the discrete coating comprises contacting the substrate with the coated transfer sheet while the transfer sheet remains horizontal and rotating the coated transfer sheet together with the substrate such that substrate is beneath the transfer sheet.  
   
   
       6 . The method of  claim 1  wherein the step of transferring the discrete coating comprising transferring a coating from a transfer sheet to a substrate in a rotational framework.  
   
   
       7 . The method of  claim 1  wherein each discrete coating is an area corresponding to a single plasma display panel.  
   
   
       8 . The method of  claim 1  wherein each discrete coating has an area ranging from about 1 cm 2  to about 2 m 2 .  
   
   
       9 . The method of  claim 1  wherein the transfer sheet comprises a flexible film and a rigid support layer.  
   
   
       10 . The method of  claim 1  wherein the flexible film is removed concurrently with removing the rigid support layer.  
   
   
       11 . The method of  claim 1  wherein the substrate is a glass panel optionally comprising an electrode pattern  
   
   
       12 . The method of  claim 1  wherein the discrete coatings are provided with a template.  
   
   
       13 . The method of  claim 1  wherein the mold is transparent.  
   
   
       14 . The method of  claim 1  wherein the curable composition is cured through the mold, cured through the substrate, or a combination thereof.  
   
   
       15 . The method of  claim 1  wherein the mold is flexible.  
   
   
       16 . The method of  claim 1  wherein the method is at least semi-automated.  
   
   
       17 . The method of  claim 1  wherein the curable composition comprises diluent is an amount of at least 2 wt-%, at least 5 wt-% or at least 10 wt-%.  
   
   
       18 . The method of  claim 1  wherein the slurry has a viscosity of less than 20,000 cps less than 5,000 cps.  
   
   
       19 . The method of  claim 1  wherein two or more discrete coatings are transferred onto a single glass panel.  
   
   
       20 . A method of making an article comprising: 
 providing a transfer sheet;    coating the transfer sheet with at least one discrete coating of a curable material;    transferring the discrete coating onto a substrate; and    contacting the discrete coating with a microstructured mold surface;    curing the curable material; and    removing the mold.